Meet The Team
The Lean Quest Team is a group of dedicated, determined, and deeply experienced individuals who specialize in the optimization of entire supply chains for our Clients using Lean Methods while training our Clients to be self-sufficient in the implementation of Lean Methods. We have engaged with clients in a variety of industries and departments. Check out our clients page for details. Although we cover all aspects of Lean Design, we specialize in the following:
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Business Plan development and deployment
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Operational efficiency design and modeling - Current and new facilities; process and storage
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KPI development and deployment
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Lead-time and inventory reduction strategies
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Continuous Improvement workshops - Problem Solving
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Organizational Culture design and development
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Strategic thinking and planning
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Value stream mapping
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Tel: 310.629.3233
Chuck Emery brings over 16 years of experience at Toyota's Information Systems Department, specializing in Lean implementation within service parts logistics. As one of the founders of Lean Quest, he leverages this deep expertise to transform supply chains and optimize systems for clients across diverse industries.
Key Highlights:
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Toyota Legacy: Designed and developed critical systems at Toyota, including an automated warehouse control system (Toyota's most automated) and a global warehouse management system template.
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Training & Education: Led the creation and implementation of department-wide education and training strategies, serving as a model for Toyota University.
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Strategic Leadership: Developed business and technology strategies for Toyota's North American Service Parts Division, integrating Lean concepts and advanced planning systems.
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Lean Quest Founder: Since 2002, has worked with clients like the U.S. Department of Defense Logistics Agency, Aldi, Suncorp, Parker Hannifin, Caterpillar, Chrysler, GM, and Wahl Clipper, implementing Lean methodologies.
Core Competencies:
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Lean Implementation & Supply Chain Optimization
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Warehouse Management Systems Design & Development
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Business & Technology Strategy
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Education & Training Development
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Tel: 321.332.4700
With over 28 years in warehousing and distribution, Luis Quinones brings 26 years of focused Lean Implementation expertise. He transforms operations, drives efficiency, and delivers significant cost savings.
Key Highlights:
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Toyota & Chrysler Legacy: Built a robust Lean foundation at Toyota's North American Parts Operations and spearheaded Lean deployment at Chrysler's Mopar Distribution Network, creating their first Lean Model.
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Proven Results: Achieved 92% reduction in delivery delays, 37% improvement in order cut-off to delivery lead time, and over 100% increase in outbound productivity for clients.
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Strategic Leadership: Forged key relationships between labor unions and management, embedding Lean principles in national contracts. Served as Senior Contract Manager for Lean Adoption Initiatives at Defense Distribution Centers.
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Lean Quest Impact: Since 2008, has led major process redesigns, launched new distribution centers, and optimized storage for clients like Bosch, U.S. Defense Logistics Agency, Navistar, and Aldi.
Core Competencies:
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Lean Implementation & Process Optimization
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Distribution Center Design & Launch
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Cost Reduction & Storage Optimization
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Labor Relations & Change Management
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Tel: 512.767.8345
Mike Spalding brings over 35 years of experience in Warehousing, Distribution, and Supply Chain Management. He combines extensive IT expertise with 10 years of focused Lean implementation to drive efficiency and optimization across the supply chain.
Key Highlights:
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Mercedes-Benz Expertise: Played a key role in developing and installing a new Warehouse Management System (WMS) for MBUSA OEM Parts Network. Optimized U.S. Parts Distribution Centers' space utilization and processes, and developed inventory control procedures.
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Chrysler Lean Leadership: Participated in launching Mopar's first Lean Model Parts Distribution Center and deployed Lean Storage across 21 regional and 4 national PDCs. Designed a benchmark Warehouse Productivity Tracking and Reporting database integrated with the WMS, used at 26 NAFTA locations.
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Retail Lean Impact: Implemented Lean inbound process flows in retail environments, improving back-room space utilization and significantly reducing dock-to-shelf time.
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Lean Quest Focus: Since 2010, has concentrated on developing operational tools that leverage Lean Thinking.
Core Competencies:
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Lean Implementation & Process Optimization
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Warehouse Management Systems (WMS) Design & Implementation
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Inventory Control & Optimization
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Productivity Tracking & Reporting
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Tel: 810.347.6262
Scott Hans brings over 35 years of extensive supply chain experience with industry leaders like Toyota, Case New Holland, and General Motors. He combines North American and Global leadership roles to drive Lean continuous improvement and operational excellence.
Key Highlights:
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Toyota Foundation: Led the Supply Chain Management team at Toyota, implementing daily ordering of North American sourced service parts, including logistics design and supplier development. Executed Lean principles and continuous improvement under the Toyota Production System (TPS) at multiple distribution centers.
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General Motors Leadership: Held diverse leadership roles at GM, including leading North American Operations for all Distribution Centers for GM Service Parts and leading the Global Supply Chain organization responsible for forecasting, scheduling, and delivering service parts worldwide.
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Global & North American Expertise: Held leadership roles in Distribution Operations, Logistics, Manufacturing Materials Management, and Lean Warehouse Operations, driving Lean thinking and execution.
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Lean Quest Impact: Since joining in 2020, has made significant contributions to client projects, delivering positive results through teaching Lean foundations, applying Lean tools, and mentoring organizations in problem-solving.
Core Competencies:
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Lean Continuous Improvement & Execution
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Supply Chain Management & Optimization
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Global Logistics & Operations
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Supplier Management & Procurement
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Leadership Development & Mentoring
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Tel: 313.405.5445
Bill Fish boasts over 35 years of extensive supply chain and operations leadership experience, with deep expertise in the Toyota Production System (TPS) and Lean methodologies. He has held key roles at industry leaders such as Rinehart Racing, Electrolux, NUMMI, and General Motors, driving significant improvements in efficiency, quality, and cost savings.
Key Highlights:
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NUMMI & TPS Immersion: One of 16 GM Managers selected for an intensive assignment at NUMMI, directly learning and implementing TPS with Toyota's development team.
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Global Leadership & Start-Up Expertise: Successfully launched new service parts operations for Saab Cars North America, managing two distribution centers and achieving 93% on-time delivery. Extensive experience with foreign supply bases and import processes.
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General Motors Legacy: Held diverse leadership roles at GM, including Director of Supply Chain, Director of Quality System, Plant Manager, and Manager Business System Improvement Team.
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Significant Cost & Quality Improvements: Achieved $250,000 annual savings by replacing a non-performing packaging operation at Electrolux. Achieved productivity improvements ranging from 37.2% to 74.0% in Brazilian spare parts facilities.
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Consulting Impact: Supported lean manufacturing implementation at nuclear submarine and aircraft carrier fabrication operations. Implemented Lean warehousing and distribution processes in Brazil. Developed and implemented assembly cells for various products, including automotive door panels, motorcycle exhaust systems, and door inner assemblies.
Core Competencies:
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Toyota Production System (TPS) & Lean Implementation
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Supply Chain & Operations Management
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Quality Systems & Process Improvement
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International Operations & Foreign Supply Base Management
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Safety Process Development & Implementation
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Tel: 612.327.9122
Dennis Berkowitz brings over 40 years of experience across the distribution and manufacturing sectors, including 20+ years at The Toro Company, specializing in Lean practices, inventory management, sales, and marketing. He drives efficiency, increases profitability, and enhances customer service through strategic planning and process improvement.
Key Highlights:
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Inventory Innovation: Developed, piloted, and launched the "Sell One Buy One" inventory approach, significantly reducing stock-outs, increasing inventory turns, and improving warehouse efficiencies for both Toro and its customers.
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Lean Training & Implementation: Presented numerous workshops on Lean practices, including Value Stream Mapping, 5 Why training, 5S training, Kaizen events, and leadership brainstorming. Developed and led training sessions for 30+ parts attendees globally.
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Sales & Marketing Leadership: Hired, managed, and developed effective sales and marketing representatives. Created and developed strategic parts blitzes, resulting in increased sales and market awareness.
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Customer Service Enhancement: Launched the first-ever online customer service training for parts employees, improving interaction and effectiveness.
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Operational Excellence: Contributed to numerous Lean improvements for The Toro Warehouse Distribution Center, with annual sales exceeding $345 million. Planned shipments to consistently meet or exceed quarterly and annual goals while reducing waste and errors.
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Strategic Planning & Growth: Proven aptitude for strategizing to accelerate growth and revenue, capture market share, and unify sales and service teams. Focused on "action planning" for effective results.
Core Competencies:
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Lean Practices & Implementation
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Inventory Management & Optimization
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Sales & Marketing Strategy
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Training & Development
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Customer Service Improvement
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Strategic Planning & Revenue Growth
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Tel: 916.704.4604
Guy Olivier brings over 35 years of experience in Lean Manufacturing and Engineering, beginning with an intensive management training program at Toyota. He specializes in driving Lean transformations, implementing business systems, and achieving significant operational improvements across diverse industries.
Key Highlights:
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Toyota Foundation: Graduate of the "Toyota Management" program, a 3-year full-time program focused on management development and TPS (Toyota Production System). Managed Process Engineering and new model introductions, including the Toyota Camry. Led supplier turnaround teams to implement Just-In-Time (JIT) manufacturing.
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Diverse Industry Experience: Held senior management positions in textiles, aerospace, medical, and semiconductors. Established Lean supply chain solutions with market leaders like Applied Materials and Siemens Medical. Developed Lean manufacturing processes for jet-powered UAVs and missile programs at Composite Engineering Inc.
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Systems & Certifications: Led the implementation of ERP systems, achieved ISO9001, ISO13485, and AS9100 certifications, and managed multiple facilities at the P&L level.
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Quantifiable Results: Achieved Gold Performance metrics from Boeing and "Most Improved Supplier" & "Best Practice in Quality" awards from Siemens Medical. Increased throughput from 2 to 8 million yards of textile processing per month. Reduced inventories by 40%, reduced lead times, and reduced reworks to below 3%. Achieved an average of 18.2% EBITDA during an economic downturn.
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Consulting Expertise: Since 2006, has helped commercial and government organizations streamline operations, improve quality, and eliminate waste. Applied Lean thinking to manufacturing, administrative, HR, NPD, sales, and project-based programs like ISO and ERP implementation.
Core Competencies:
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Toyota Production System (TPS) & Lean Manufacturing
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Process Engineering & Management
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Supply Chain Optimization
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ERP & Business Systems Implementation
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ISO & Quality Certifications (ISO9001, ISO13485, AS9100)
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Tel: 949.254.0659
Dave Graham brings 17 years of experience at Toyota Motor Sales, specializing in Lean implementation across the aftermarket parts supply chain and distribution operations. Since 2002, as one of the founders of Lean Quest, he has leveraged this expertise to drive significant improvements for clients across diverse industries. While currently enjoying semi-retirement, Dave remains available for select contract opportunities.
Key Highlights:
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Toyota Lean Foundation: Implemented Lean concepts in multiple distribution centers, piloted and rolled out Lean outbound supply chain concepts, and led Continuous Improvement Training & Development. Designed, launched, and operated North American Parts Centers, including inbound logistics from suppliers.
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Strategic Network Development: Developed and executed a Lean warehouse network strategy for a $4 billion aftermarket network.
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Quantifiable Results: Achieved productivity improvements of 15%+, space reductions of 30-50%, quality improvements up to 50%, delivery compliance increases of 25-50%, staffing reductions up to 20%, and morale improvements up to 93% through Lean Operations implementation.
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Value Stream Optimization: Led Value Stream continuous improvement activities, resulting in lead time reductions of 25-75%.
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Industry Expertise: Worked with clients in automotive, defense, grocery, consumer products, heavy equipment, certification laboratories, banking, and more.
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Training & Education: Designed and delivered workshops for the Lean Enterprise Institute and Georgia Institute of Technology.
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Lean Quest Founder: Since 2002, has worked with clients like the U.S. Department of Defense Logistics Agency, Oshkosh Defense, Mopar, GM, Keystone Automotive, Meritor, Bosch, DDI, Manitou, Caterpillar, Caterpillar 3PL, implementing Lean methodologies.
Core Competencies:
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Lean Implementation & Process Optimization
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Aftermarket Supply Chain Management
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Value Stream Mapping & Improvement
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Training & Development
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Strategic Network Planning
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Tel: 949.254.0269
Alan Noss is a highly experienced Lean Management consultant with hands-on implementation experience across global organizations, including Toyota, Caterpillar, Chrysler, and Suncorp. As one of the founders of Lean Quest, he specializes in Toyota Production System (TPS) implementation, leveraging 13 years at Toyota's Service Parts Logistics Division. While currently enjoying semi-retirement, Alan remains available for select contract opportunities.
Key Highlights:
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Toyota Legacy: Spent 13 years at Toyota, responsible for ongoing Lean training, development, and implementation throughout the supply chain. Implemented the first regional rollout of Just-In-Time (JIT) deliveries to dealerships, resulting in significant savings and efficiency improvements.
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Global Program Leadership: Led a 4-year enterprise-wide Lean program for a $16 billion insurance and financial institution in Australia, improving business processes and customer experience across all business units.
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Quantifiable Results: Achieved over $250,000 in annual savings per dealership through JIT delivery implementation. Reduced claims data entry times by up to 20%, improved data entry quality by 50%, and increased productivity by 25% through Lean implementation. Reduced claim processing time by 80%.
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Strategic Planning: Managed advanced planning software configuration for Toyota's B2B internet spin-off (iStarSystems) and led distribution centers in implementing Pull Systems and Lean concepts.
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Lean Quest Founder: Since 2002, has worked with clients like the U.S. Department of Defense Logistics Agency, Mercedes Benz, Michael Kors, Parker Hannifin, Oshkosh Defense, Lean Enterprise Institute, Nebraska Furniture Mart, implementing Lean methodologies.
Core Competencies:
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Toyota Production System (TPS) Implementation
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Lean Management & Continuous Improvement
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Supply Chain Optimization
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Just-In-Time (JIT) Delivery
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Value Stream Mapping & Process Improvement
